A.O. Smith SBD 30 150 User Manual

MODELS SBD 30 150 AND SBD 30 199

COMMERCIAL GAS, GLASS-LINED, TANK-TYPE WATER HEATER

• INSTALLATION • OPERATION • MAINTENANCE • LIMITED WARRANTY

Thank you for buying this energy efficient water heater from
A.O. Smith Water Products Company. We appreciate your
confidence in our products.

CAUTION

TEXT IN BLACK BOLD TYPE OR UNDERLINED CONTAINS
INFORMA TION RELA TIVE TO YOUR SAFETY. PLEASE READ
THOROUGHLY BEFORE INSTALLING AND USING THIS
APPLIANCE.

500 LINDAHL P ARKWA Y

ASHLAND CITY , TN 37015

www.statewaterheaters.com

PLACE THESE INSTRUCTIONS ADJACENT TO HEATER

AND NOTIFY OWNER TO KEEP FOR FUTURE REFERENCE.

Printed in U.S.A. 1004 PART NO. 196310-001

1

ROUGH-IN-DIMENSIONS

FIGURE 1

T ABLE 1 - HEA TER PERFORMANCE DAT A

Input Approx. RECOVERY RA TING CAP ACITIES (GPH) AT TEMPERA TURE RISE SHOWN

Model Btuh Cap. Eff. % C 11 °C 17°C 22°C 28°C 33°C 39°C 44°C 50°C 56°C 61°C 67°C 72°C 78°C

SBD 30 150 150,000 NAT 32 Gal 80 G PH 727 485 364 291 242 208 182 162 145 132 121 112 104

SBD 30 150 150,000 LP 32 Gal 80 GPH 727 485 364 291 242 208 182 162 145 132 121 112 104

SBD 30 199 199,900 NAT 32 Gal 80 G PH 969 646 485 388 323 277 242 215 194 176 162 149 139

SBD 30 199 182,000 LP 32 Gal 80 GPH 882 588 441 353 294 252 221 196 177 160 147 136 126

Rate Tank Approx. F 20°F 30°F 40°F 50°F 60°F 70°F 80°F 90°F 100°F 110°F 120°F 130°F 140°F

44 kW/Hr . NA T 121 Litres L P H 2752 1836 1378 1102 916 787 689 613 549 500 458 424 394

44 kW/Hr. LP 121 Litres LP H 2752 1836 1378 1102 916 787 689 613 549 500 458 424 394

59 kW/Hr . NA T 121 Litres LPH 3668 2445 1836 1469 1223 1049 916 814 734 666 613 564 526

53 kW/Hr. LP 121 Litres LP H 3339 2226 1669 1336 1113 954 837 742 670 606 557 515 477

FOREWORD

These designs comply with ANSI Z21.10.3 as a Booster type
water heater.

Detailed installation diagrams are found in this manual. These
diagrams will serve to provide the installer with a reference for
the materials and methods of piping necessary. It is highly
essential that all water, gas piping and wiring be installed as
shown on the diagrams.

Particular attention should be given to the installation of
thermometers at the locations indicated on the diagrams as
these are necessary for checking the proper functioning of the
heater.

The heater is designed to operate on natural gas.

These heaters may be installed on combustible floors.
In addition to these instructions, the equipment shall be installed

in accordance with those installation regulations in force in the
local area where the installation is to be made. These shall be
carefully followed in all cases. Authorities having jurisdiction
should be consulted before installations are made.

The installation must conform to these instructions and the local
code authority having jurisdiction. In the absence of local codes,
the installation must comply with the latest editions of the
National Fuel Gas Code, ANSI Z223.1/NFPA 54 and the National
Electrical Code, NFPA 70, documents are available from the
National Fire Protection Association, 1 Batterymarch Park, Quincy ,
MA 02269.

2

TABLE OF CONTENTS

Page Page

ROUGH-IN-DIMENSIONS ..................................................... 2

FOREWORD.......................................................................... 2

GENERAL SAFETY INFORMA TION ....................................... 3

Precautions ....................................................................... 3

Grounding Instructions ...................................................... 3

Chemical Vapor Corrosion................................................ 3

Improper Combustion ......................................................3-4

Extended Non-Use ............................................................ 4

Insulation Blankets ............................................................ 4

High Altitude Installation .................................................... 4

FEATURES ............................................................................ 4

Self-Cleaning Hydro-Cannon ............................................ 4

High Limit Switch .............................................................. 4-5

Electronic Ignition Control ................................................. 5

Exhaust Inducer (Blower Assy.) ......................................... 5

Circulating Pump ............................................................... 5

Dishwashing Machine Requirement ................................ 5

INSTALLATION INSTRUCTIONS........................................... 6

Required Ability.................................................................. 6

Uncrating ........................................................................... 6

Locating The Heater.......................................................... 6

Levelling ............................................................................ 6

Clearances........................................................................ 6

Air Requirements .............................................................6-7

Venting ..............................................................................7-8

Multiple Heater Manifold.................................................... 8

Water Line Connections ................................................... 8

Water (Potable) Heating and Space Heating .................... 8

Thermometers (Not Supplied) .......................................... 8

Relief Valve ........................................................................ 8

Gas Piping ......................................................................... 9

Gas Pressure Regulator ................................................ 9-10

Heater Wiring .................................................................... 10

INSTALLA TION DIAGRAMS................................................11-17

OPERATION......................................................................... 18

General............................................................................ 18

SEQUENCE OF OPERATION.............................................. 18

Lighting and Operation .................................................... 19

Water Temperature Control............................................. 20

PREVENTIVE MAINTENANCE ............................................ 20

Check The Ignitor Assembly ........................................... 20

Ignitor Assembly .............................................................. 20

Main Burner ................................................................... 20-21

Gas Valves....................................................................... 21

Checking The Input ......................................................... 2 1

Venting System................................................................ 2 1

Remote Storage Tank Temperature Control ................... 21

Relief Valve ...................................................................... 22

Hot Water Odor ................................................................ 22

Anode Rod Inspection ..................................................... 2 2

Flushing ........................................................................... 22

Draining........................................................................... 22

Recommended Procedure For Periodic
Removal of Lime Deposits From Tank Type

Commercial Water Heaters ..........................................22-23

Deliming Solvents ........................................................... 23

Tank Cleanout Procedures ...........................................23-24

Ignition Module System ................................................... 24

System Diagnostics ........................................................ 24

SERVICE ............................................................................. 24

Electrical Servicing .......................................................... 24

Replacement Parts ......................................................... 24

Sequence of Operation Flow Chart................................. 25

Operational Checklist ...................................................... 26

Limited Warranty ............................................................. 27

GENERAL SAFETY INFORMA TION

PRECAUTIONS

DO NOT USE THIS APPLIANCE IF ANY PA RT HAS BEEN UNDER
WA TER. Immediately call a qualified service technician to inspect
the appliance and to replace any part of the control system and
any gas control which has been under water.

IF THE UNIT IS EXPOSED TO THE FOLLOWING, DO NOT
OPERATE HEATER UNTIL ALL CORRECTIVE STEPS HAVE
BEEN MADE BY A QUALIFIED SERVICEMAN.

1. EXTERNAL FIRE.

2. DAMAGE.

3. FIRING WITHOUT WA TER.

4. SOOTING

GROUNDING INSTRUCTIONS

This water heater must be grounded in accordance with the
National Electric Code and/or local codes. These must be
followed in all cases.

This water heater must be connected to a grounded metal,
permanent wiring system; or an equipment grounding conductor
must be run with the circuit conductors and connected to the
equipment grounding terminal or lead on the water heater, see
Figure 9.

CHEMICAL VAPOR CORROSION

WARNING

CORROSION OF THE FLUEWAYS AND VENT SYSTEM MAY
OCCUR IF AIR FOR COMBUSTION CONTAINS CERTAIN
CHEMICAL VAPORS. SUCH CORROSION MAY RESULT IN
FAILURE AND RISK OF ASPHYXIA TION.

Spray can propellants, cleaning solvents, refrigerator and air
conditioning refrigerants, swimming pool chemicals, calcium
and sodium chloride (water softener salt), waxes, and process
chemicals and typical compounds which are potentially corrosive.
Do not store products of this sort near the heater. Also, air which
is brought in contact with a the heater should not contain any of
these chemicals. If necessary, uncontaminated air should be
obtained from remote or outside sources. The limited warranty
is voided when failure of water heater is due to a corrosive
atmosphere. (Refer to the limited warranty for complete terms
and conditions.

IMPROPER COMBUSTION

WARNING

ATTIC AND/OR EXHAUST FANS OPERA TING ON THE PREMISES
WITH A W ATER HEA TER CAN RESUL T IN CARBON MONOXIDE
POISONING AND DEATH.

3

OPERATION OF THESE FANS CAN PRODUCE A NEGATIVE
DRAFT IN THE AREA OF THE WATER HEA TER PREVENTING
THE PRODUCTS OF COMBUSTION FROM EXHAUSTING
THROUGH THE CHIMNEY OR VENT PIPE.

The venting of the water heater should be inspected by a qualified
service technician at the time of installation and periodically
thereafter to ensure a down-draft condition does not exist.

DO NOT OBSTRUCT THE FLOW OF COMBUSTION AND
VENTILATING AIR. ADEQUA TE AIR FOR COMBUSTION AND
VENTILATION MUST BE PROVIDED FOR SAFE OPERA TION.

EXTENDED NON-USE PERIODS

WARNING

HYDROGEN GAS CAN BE PRODUCED IN A HOT W A TER SYSTEM
SERVED BY THIS HEA TER THA T HAS NOT BEEN USED FOR A
LONG PERIOD OF TIME (GENERALL Y TWO WEEKS OR MORE).
HYDROGEN GAS IS EXTREMEL Y FLAMMABLE.

risk of injury under these conditions, it is recommended that the
hot water faucet be opened for several minutes at the kitchen
sink before using any electrical appliance connected to the hot
water system. If hydrogen is present, there will probably be an
unusual sound such as air escaping through the pipe as the
water begins to flow. THERE SHOULD BE NO SMOKING OR

OPEN FLAME NEAR THE FAUCET AT THE TIME IT IS OPEN.

T o reduce the

INSULATION BLANKETS

Insulation blankets available to the general public for external
use on gas water heaters are not approved for use on your
State water heater. The purpose of an insulation blanket is to
reduce the standby heat loss encountered with storage tank
water heaters. Your State water heater meets or exceeds
the ASHRAE/IES 90.1-1999 standards with respect to
insulation and standby loss requirement making an insulation
blanket unnecessary.

WARNING

Should you choose to apply an insulation blanket to this heater,
you should follow these instructions. Failure to follow these
instructions can result in fire, asphyxiation, serious personal
injury or death.

• Do not apply insulation to the top of the water heater, as
this will interfere with safe operation of drafthood.

• Do not cover the temperature & pressure relief valve.

• Do not cover the instruction manual. Keep it on the side of
the water heater or nearby for future reference.

• Do obtain new labels from State Water Heaters for
placement on the blanket directly over the existing labels.

HIGH AL TITUDE INST ALLATIONS

As elevation above sea level is increased, there is less oxygen
per cubic foot of air. Therefore, the heater input rate should be
reduced at high altitudes for satisfactory operation with the
reduced oxygen supply. Failure to make this reduction would
result in an overfiring of the heater causing sooting, poor
combustion and/or unsatisfactory heater performance.

REQUIREMENTS

Ratings specified by manufacturers for most appliances apply
for elevations up to 2000 feet. For elevations above 2000 feet,
ratings must be reduced at the rate of 4% for each 1000 feet
above sea level. For example, if a heater is rated at
120,000 Btuh at sea level, to rate the heater at 4000 feet, you
subtract 4 (once for each thousand feet) x.04 (4% input reduction)
x 120,000 Btuh (original rating) from the original rating. Therefore,
to calculate the input rating at 4,000 feet: 4 x .04 x 120,000 =19,200
Btuh, 120,000 - 19,200 = 100,800 Btuh. At 6000 feet the correct
input rating should be 91,200 Btuh.

The input reduction is primarily achieved by reducing the size of
the main burner orifices. To do this, the main burner orifices
require replacement with orifices sized for the particular
installation elevation. Correct orifice sizing and parts may be
obtained from State Water Heaters. When ordering, be sure to
state the model number and the altitude of the location where
the water heater is being installed.

Upon completion of derating of the heater, adjustment to the gas
pressure regulator may be required. See CHECKING THE
INPUT section in this manual for inlet and manifold pressure
requirements.

Also due to the input rating reduction required at high altitudes,
the output rating of the appliance is also reduced and should be
compensated for in the sizing of the equipment for application.

FEATURES

SELF-CLEANING HYDRO-CANNON

These units include a self-cleaning hydro-cannon installed in
the front water inlet. See figure 2. The hydro-cannon must be
oriented correctly for proper function. There is a marked range
on the pipe nipple portion of the hydro-cannon, that must be
aligned with the top of the inlet spud. A label above the jacket
hole has an arrow that will point to the marked portion of the
pipe nipple if the orientation is correct. If the arrow does not
point within the marked range on the pipe nipple, adjust the pipe
nipple to correct. A pipe union is supplied with the hydro-cannon
to reduce the probability of misaligning the hydro-cannon
accidentally while tightening the connection to the inlet water
supply line. Improper orientation of the hydro-canon can cause
poor performance of the heater and can significantly reduce
outlet water temperatures during heavy draws.

WARNING

INST ALLA TIONS ABOVE 2000 FEET (610 METERS) REQUIRE
REPLACEMENT OF THE BURNER ORIFICE IN ACCORDANCE
WITH SECTION 8.1.2 OF THE NATIONAL FUEL GAS CODE
(ANSI Z223.1). FAILURE TO REPLACE THE ORIFICE WILL RESULT
IN IMPROPER AND INEFFICIENT OPERA TION OF THE APPLIANCE
RESUL TING IN THE PRODUCTION OF INCREASED LEVELS OF
CARBON MONOXIDE GAS IN EXCESS OF SAFE LIMITS WHICH
COULD RESULT IN SERIOUS PERSONAL INJUR Y OR DEA TH.

You should contact your gas supplier for any specific changes
which may be required in your area.

NOTE: The inlet may have 1, 2 or 7 cross- tubes.

FIGURE 2

HIGH LIMIT SWITCH

The digital thermostat (Figure 3) contains the high limit (energy
cutoff) sensor. The high limit switch interrupts main burner gas
flow should the water temperature reach 203°F (195°C).

4

In the event of high limit switch operation, the appliance cannot
be restarted unless the water temperature is reduced to
approximately 120°F (49°C). The high limit reset button on the
front of the control then needs to be depressed.

Continued manual resetting of high limit control, preceded by
higher than usual water temperature is evidence of high limit
switch operation. The following is a possible reason for high
limit switch operation.

A malfunction in the thermostatic controls would allow the gas
valve to remain open causing water temperature to exceed the
thermostat setting. The water temperature would continue to
rise until high limit switch operation.

Contact your dealer or service agent if continued high limit
switch operation occurs.

EXHAUST INDUCER (BLOWER ASSEMBLY)

All units are equipped with a exhaust inducer. The inducer
assists in drawing in fresh air to the unit for combustion and
then assists in dispensing the combustion by-products into the
venting leading outside.

The exhaust inducer is equipped with a gravity controlled damper
to reduce the amount of heat loss through the flue, improving
efficiency.

FIGURE 5 - EXHAUST INDUCER

FIGURE 3 - DIGIT AL THERMOSTA T

ELECTRONIC IGNITION CONTROL

Each heater is equipped with a ignition module. The solid state
ignition control (Figure 4), ignites the main burner by utilizing a
silicone nitride ignitor. The silicone nitride ignitor shut s off during
the heating cycle and the main burner flame is sensed through
a remote flame sensor integral to the silicone nitride ignitor
assembly. The ignition control will try to ignite the main burner
three times before lockout. Then it waits one hour before trying
again to ignite the main burners. This is a continuous cycle.

CIRCULATING PUMP

A circulating pump is used when a system requires a circulating
loop or there is a storage tank used in conjunction with the
heater. Refer to the piping diagrams at rear of manual for electrical
hookup information and install in accordance with the latest
version of the National Electric Code ANSI/NFPA No. 70.

Only all bronze circulators are used with commercial water
heaters.

Although circulators are oiled and operated by the manufacturer
some circulators must be oiled again before operating. Please
refer to manufacturer’s instructions.

DISHWASHING MACHINE REQUIREMENT

These appliances meet the National Sanitation Foundation
Standard for sanitary installations when used with the following
leg kits, Part No’s. 6570-0 and 6570-7.

All dishwashing machines meeting the National Sanitation
Foundation requirements are designed to operate with water
flow pressures between 15 and 25 psi. Flow pressures above
25 psi, or below 15 psi, will result in improperly sanitized dishes.
Where pressures are high, a water pressure reducing or flow
regulating control valve should be used in 180°F (82°C) line to
the dishwashing machine, and should be adjusted to deliver
water between these limits.

FIGURE 4 - IGNITION CONTROL BOARD

The National Sanitation Foundation also recommends
circulation of 180
should be very gentle so that it does not cause any unnecessary
turbulence inside the water heater. The circulation should be
just enough to provide 1800F water at the point of take-off to the
dishwashing machine. Adjust flow by means of the plug cock in
the circulating line.

5

0

F water. Where this is done, the circulation

INST ALLATION INSTRUCTIONS

REQUIRED ABILITY

INSTALLATION OR SERVICE OF THIS WATER HEATER
REQUIRES ABILITY EQUIVALENT TO THAT OF A LICENSED
TRADESMAN IN THE FIELD INVOLVED. PLUMBING, AIR
SUPPLY, VENTING , GAS SUPPL Y AND ELECTRICAL WORK ARE
REQUIRED.

WHEN SUCH LOCA TIONS CANNOT BE A VOIDED, A SUIT ABLE
DRAIN P AN SHOULD BE INSTALLED UNDER THE HEA TER. Such

pans should be fabricated with sides at least 2" deep, with length
and width at least 2" greater than the diameter of the heater and
must be piped to an adequate drain. The pan must not restrict
combustion air flow.

For appliance installation locations with elevations above
2000 feet (610m), refer to HIGH ALTITUDE INSTALLATIONS
section of this manual for input reduction procedure.

WARNING

FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESUL T IN
SERIOUS PERSONAL INJURY OR DEA TH.

UNCRATING

The heater is shipped with the inducer already installed. The
wiring conduit runs from the thermostat to the inducer. Before
turning unit on, check to make sure the wiring conduit is securely
plugged into the inducer.

LOCATING THE HEATER

WARNING

THERE IS A RISK IN USING FUEL BURNING APPLIANCES SUCH
AS GAS WA TER HEA TERS IN ROOMS, GARAGES OR OTHER
AREAS WHERE GASOLINE, OTHER FLAMMABLE LIQUIDS OR
ENGINE DRIVEN EQUIPMENT OR VEHICLES ARE STORED,
OPERA TED OR REPAIRED. FLAMMABLE V APORS ARE HEA VY
AND TRAVEL ALONG THE FLOOR AND MA Y BE IGNITED BY THE
HEATER’S PILOT OR MAIN BURNER FLAMES CAUSING FIRE OR
EXPLOSION. SOME LOCAL CODES PERMIT OPERA TION OF
GAS APPLIANCES IN SUCH AREAS IF THEY ARE INST ALLED 18”
OR MORE ABOVE THE FLOOR. THIS MA Y REDUCE THE RISK IF
LOCA TION IN SUCH AN AREA CANNOT BE A VOIDED.

DO NOT INSTALL THIS WATER HEATER DIRECTLY ON A
CARPETED FLOOR. A FIRE HAZARD MA Y RESULT. Instead the

water heater must be placed on a metal or wood panel extending
beyond the full width and depth by at least 3 inches in any direction.
If the heater is installed in a carpeted alcove, the entire floor
shall be covered by the panel. Also, see the DRAINING
requirements in MAINTENANCE Section.

THE HEATER SHALL BE LOCATED OR PROTECTED SO IT IS NOT
SUBJECT TO PHYSICAL DAMAGE BY A MOVING VEHICLE.

WARNING

FLAMMABLE ITEMS, PRESSURIZED CONTAINERS OR ANY
OTHER POTENTIAL FIRE HAZARDOUS ARTICLES MUST NEVER
BE PLACED ON OR ADJACENT TO THE HEATER. OPEN
CONT AINERS OR FLAMMABLE MATERIAL SHOULD NOT BE
STORED OR USED IN THE SAME ROOM WITH THE HEA TER.

When installing the heater , consideration must be given to proper
location. Location selected should be as close to the stack or
chimney as practicable, with adequate air supply and as
centralized with the piping system as possible.

THE HEATER MUST NOT BE LOCA TED IN AN AREA WHERE IT
WILL BE SUBJECT TO FREEZING .

LOCA TE IT NEAR A FLOOR DRAIN. THE HEA TER SHOULD BE
LOCATED IN AN AREA WHERE LEAKAGE FROM THE HEA TER OR
CONNECTIONS WILL NOT RESULT IN DAMAGE TO THE
ADJACENT AREA OR TO LOWER FLOORS OF THE STRUCTURE.

LEVELING

If the unit is not level, insert the bolts which were used in crating
into the legs to correct this condition.

CLEARANCES

These heaters are approved for installation on combustible
flooring in an alcove when the minimum clearance from any
combustion construction are followed as indicated in figure 6.

Models SBD 30 150 and 30 199 are approved for installation on
non-cumbustible flooring or combustible flooring with leg kit
part no. 6570.

In all installations the minimum combustible clearances from
vent piping shall be 6". Vent piping passing through a combustible
wall or ceiling must be a continuous run (no joints) and retain
the 6" clearance unless an approved reducing thimble is used.

A service clearance of 24" should be maintained from serviceable
parts, such as relief valves, flue baffles, thermostats, cleanout
openings or drain valves.

The units are approved for installation with side, rear and ceiling
clearances.

AIR REQUIREMENTS

REFER TO THE LATEST EDITION OF THE "NATIONAL FUEL
GAS CODE" ANSI Z223.1/NFPA 54.

KEEP APPLIANCE AREA CLEAR AND FREE OF COMBUSTIBLE
MA TERIALS, GASOLINE AND OTHER FLAMMABLES, V APORS
AND LIQUIDS.

DO NOT OBSTRUCT THE FLOW OF COMBUSTION OR
VENTILATING AIR.

WARNING

FOR SAFE OPERATION PROVIDE ADEQUATE AIR FOR
COMBUSTION AND VENTILA TION. AN INSUFFICIENT SUPPL Y
OF AIR WILL CAUSE RECIRCULATION OF COMBUSTION
PRODUCTS RESULTING IN AIR CONTAMINA TION THA T MA Y BE
HAZARDOUS TO LIFE. SUCH A CONDITION OFTEN WILL RESUL T
IN A YELLOW, LUMINOUS BURNER FLAME, CAUSING
CARBONING OR SOOTING OF THE COMBUSTION CHAMBER,
BURNERS AND FLUE TUBES AND CREATES A RISK OF
ASPHYXIA TION.

Where an exhaust fan is supplied in the same room with a
heater, sufficient openings for air must be provided in the walls.

UNDERSIZED OPENINGS WILL CAUSE AIR TO BE DRA WN INTO
THE ROOM THROUGH THE CHIMNEY, CAUSING POOR
COMBUSTION. SOOTING MA Y RESUL T IN SERIOUS DAMAGE
TO THE HEA TER AND RISK OF FIRE OR EXPLOSION.

6

FIGURE 6 -ILLUSTRA TION OF MINIMUM CLEARANCES TO COMBUSTIBLES

UNCONFINED SPACE

In buildings of conventional frame, brick, or stone construction,
unconfined spaces may provide adequate air for combustion,
ventilation and draft hood dilution.

If the unconfined space is within a building of tight construction
(buildings using the following construction: weather stripping,
heavy insulation, caulking, vapor barrier, etc.), air for combustion,
ventilation and draft hood dilution must be obtained from
outdoors. The installation instructions for confined spaces in
tightly constructed buildings must be followed to ensure
adequate air supply.

CONFINED SPACE

When drawing combustion and dilution air from inside a
conventionally constructed building to a confined space, such a
space shall be provided with two permanent openings, ONE IN
OR WITHIN 12 INCHES OF THE ENCLOSURE TOP AND ONE
IN OR WITHIN 12 INCHES OF THE ENCLOSURE BOTTOM.
Each opening shall have a free area of at least one square inch
per 1000 Btuh of the total input of all appliances in the enclosure,
but not less than 100 square inches.

If the confined space is within a building of tight construction, air
for combustion, ventilation, must be obtained from outdoors.
When directly communicating with the outdoors or
communicating with the outdoors through vertical ducts, two
permanent openings, located in the above manner, shall be
provided. Each opening shall have a free area of not less than
one square inch per 4000 Btuh of the total input of all appliances
in the enclosure. If horizontal ducts are used, each opening
shall have a free area of not less than one square inch per
2000 Btuh of the total input of all appliances in the enclosure.

If any part of the vent system are exposed to ambient
temperatures below 40°F (4°C) it must be insulated to prevent
condensation.

The following steps shall be followed with each appliance
connected to the venting system placed in operation, while any
other appliances connected to the venting system are not in
operation.

1. Seal any unused openings in the venting system.

2. Inspect the venting system for proper size and horizontal
pitch, as required in the National Fuel Gas Code, ANSI
Z223.1. Determine that there is no blockage or restriction,
leakage, corrosion and other deficiencies which could cause
an unsafe condition.

3. So far as is practical, close all building doors and windows
and all doors between the space in which the water heater(s)
connected to the venting system are located and other
spaces of the building. Turn on all appliances not connected
to the venting system. Turn on all exhaust fans, such as
range hoods and bathroom exhausts, so they shall operate
at maximum speed. Close fireplace dampers.

4. Follow the lighting instruction. Place the water heater being
inspected in operation. Adjust thermostat so appliance shall
operate continuously.

5. After it has been determined that each appliance connected
to the venting system properly vents when tested as outlined
above, return doors, windows, exhaust fans, fireplace
dampers and any other gas burning appliance to their
previous conditions of use.

6. If improper venting is observed during any of the above tests,
the venting system must be corrected.

WARNING

FAILURE TO CORRECT BACK DRAFTS MAY CAUSE A IR
CONTAMINA TION AND UNSAFE CONDITIONS.

VENTING

WARNING

THE INSTRUCTIONS IN THIS SECTION ON VENTING MUST
BE FOLLOWED TO AVOID CHOKED COMBUSTION OR
RECIRCULATION OF FLUE GASES. SUCH CONDITIONS
CAUSE SOOTING OR RISKS OF FIRE AND ASPHYXIATION.

Heater must be protected from freezing downdrafts.
Remove all soot or other obstructions from the chimney that will

retard a free draft.
Type B venting is recommended with these heaters.
This water heater must be vented in compliance with all local

codes, the current revision of the National Fuel Gas Code
(ANSI-Z223.1) and with the Category I Venting Tables.

• If the back draft cannot be corrected by the normal method or

if a suitable draft cannot be obtained, a blower type flue gas
exhauster must be employed to assure proper venting and
correct combustion.

• Do not connect the heater to a common vent or chimney with

solid fuel burning equipment. This practice is prohibited by
many local building codes as is the practice of venting gas
fired equipment to the duct work of ventilation systems.

FIGURE 7

7

• Where a separate vent connection is not available and the
vent pipe from the heater must be connected to a common
vent with an oil burning furnace, the vent pipe should enter
the smaller common vent or chimney at a point above the
large vent pipe.

MULTIPLE HEATER MANIFOLD

When horizontally manifolding two or more heaters vent as
shown in Figure 8. Refer to NFPA 54/ANSI Z223.1 for venting
multiple heaters.

FIGURE 8

WATER LINE CONNECTIONS

This manual provides detailed installation diagrams (see pages
12-17 of this manual) for typical methods of application for the
water heaters.

The water heater may be installed by itself, or with a separate
storage tank, on both single and two-temperature systems.
When used with a separate storage tank, the circulation may be
either by gravity or by means of a circulating pump. When a
circulating pump is used it is important to note that the flow rate
should be slow so that there will be a minimum of turbulence
inside the heater.

If a water heater is installed in a closed water system, contact
the water supplier or local plumbing inspector on how to control
this situation.

WATER (POT ABLE) HEATING

AND SPACE HEATING

1. All piping components connected to this unit for space heating
applications shall be suitable for use with potable water.

(without bypass) is installed in the cold water line between
the water heater and street main (or well).

Excessive pressure may develop in such closed systems,
causing premature tank failure or intermittent relief valve
operation.
or a similar device may be required in the inlet supply line
between the appliance and the meter or valve to compensate
for the thermal expansion of the water.

SYSTEM CONNECTIONS

The system installation must conform to these instructions and
to the local code authority having jurisdiction. Good practice
requires that all heavy piping be supported.

This is not a warranty failure. An expansion tank

THERMOMETERS (Not Supplied)

Thermometers should be obtained and field installed as shown
in the installation diagrams.

Thermometers are installed in the system as a means of
detecting the temperature of the outlet water supply.

RELIEF VA LVE

This water heater is equipped with a combination
temperature-pressure relief valve that complies with the standard
for relief valves and automatic gas shutoff devices for hot water
supply system, ANSI Z21.22. FOR SAFE OPERA TION OF THE

WA TER HEA TER, THE RELIEF VAL VE(S) MUST NOT BE REMOVED
OR PLUGGED.

ASME ratings cover pressure relief capacities. A.G.A. ratings
cover release rate with temperature actuation.

In addition to the appliance relief valve, each remote storage
tank which may be used in conjunction with this appliance shall
also be installed with a properly sized, rated and approved
combination temperature (ANSI) and pressure (ASME) relief
valve(s).

WARNING

THE PURPOSE OF RELIEF VALVE IS TO AVOID EXCESSIVE
PRESSURE OR TEMPERA TURE INTO THE STEAM RANGE, WHICH
MAY CAUSE SCALDING AT FIXTURES, TANK EXPLOSION,
SYSTEM OR HEATER DAMAGE. NO V AL VE IS TO BE PLACED
BETWEEN THE RELIEF V ALVE AND TANK.

2. Toxic chemicals, such as those used for boiler treatment,
shall NEVER be introduced into this system.

3. This unit may NEVER be connected to any existing heating
system or component(s) previously used with a non-potable
water heating appliance.

4. When the system requires water for space heating at
temperatures higher than required for domestic water
purposes, a tempering valve must be installed. Please refer
to installation diagrams on pages 12 thru 17 of this manual
for suggested piping arrangements.

CAUTION

A closed system will exist if a check valve (without bypass),
pressure reducing valve (without bypass), or a water meter

Your local code authority may have other specific relief valve
requirements.

A DRAIN LINE MUST BE CONNECTED T O THE RELIEF VAL VE TO
DIRECT DISCHARGE TO A SAFE LOCATION TO A VOID SCALDING
OR WA TER DAMAGE. THIS LINE MUST NOT BE REDUCED FROM
THE SIZE OF THE V AL VE OUTLET AND MUST NOT CONTAIN
VALVES, RESTRICTIONS NOR SHOULD IT BE LOCATED IN
FREEZING AREAS. DO NOT THREAD OR CAP THE END OF THIS
LINE. RESTRICTED OR BLOCKED DISCHARGE WILL DEFEA T
THE PURPOSE OF THE V AL VE AND IS UNSAFE. DISCHARGE
LINE SHALL BE INST ALLED TO ALLOW COMPLETE DRAINAGE
OF BOTH THE V AL VE AND LINE.

See SERVICE INFORMATION section for procedure and
precautions.

8

GAS PIPING

Contact your local gas service company to ensure that adequate
gas service is available and to review applicable installation
codes for your area.

Size the main gas line in accordance with Table 2. The figures
shown are for straight lengths of pipe at 0.5 in. W.C. pressure
drop, which is considered normal for low pressure systems.
Note: Fittings such as elbows, tees and line regulators will add
to the pipe pressure drop. Also refer to the latest version of the
National Fuel Gas Code.

To prevent damage, care must be taken not to apply too much
torque when attaching gas supply pipe to gas valve inlet.

Apply joint compounds (pipe dope) sparingly and only to the
male threads of pipe joints. Do not apply compounds to the first
two threads. Use compounds resistant to the action of liquefied
petroleum gases.

BEFORE PLACING THE HEA TER IN OPERATION, CHECK FOR GAS
LEAKAGE. Use soap and water solution or other material
acceptable for the purpose in locating the leaks. DO NOT USE
MATCHES, CANDLES, FLAME OR OTHER SOURCES OF IGNITION
FOR THIS PURPOSE.

WARNING

THE HEATER IS NOT INTENDED FOR OPERA TION A T HIGHER
THAN 14.0" W.C.(3.48 kPa) - NA TURAL GAS, 14.0" W .C.(3.48kPa)
EXPOSURE TO HIGHER SUPPLY PRESSURE MAY CAUSE
DAMAGE TO THE GAS V AL VE WHICH COULD RESUL T IN FIRE
OR EXPLOSION. IF OVERPRESSURE HAS OCCURRED SUCH
AS THROUGH IMPROPER TESTING OF GAS LINES OR
EMERGENCY MALFUNCTION OF THE SUPPL Y SYSTEM, THE GAS
V ALVE MUST BE CHECKED FOR SAFE OPERA TION. MAKE SURE
THAT THE OUTSIDE VENTS ON THE SUPPL Y REGULATORS AND
THE SAFETY VENT VALVES ARE PROTECTED AGAINST
BLOCKAGE. THESE ARE P ARTS OF THE GAS SUPPL Y SYSTEM,
NOT THE HEATER. VENT BLOCKAGE MA Y OCCUR DURING ICE
STORMS.

TABLE 2 - GAS SUPPLY LINE SIZES (IN INCHES)*

MAXIMUM CAPACITY OF PIPE IN CUBIC FEET PER HOUR

(Based upon a Pressure Drop of 0.5 inch Water Column and

0.6 specific Gravity Gas and max. gas pressure of 0.5 psig)

LENGTH NOMINAL IRON PIPE SIZES (INCHES)

IN FEET 1/2" 3/4" 1" 1 1/4" 1 1/2" 2" 2 1/2" 3" 4"

10 175 360 680 1400 2100 3960 6300 11000 23000
20 120 250 465 950 1460 2750 4360 7700 15800
30 97 200 375 770 1180 2200 3520 6250 12800
40 82 170 320 660 990 1900 3000 5300 10900
50 73 151 285 580 900 1680 2650 4750 9700
60 66 138 260 530 810 1520 2400 4300 8800
70 61 125 240 490 750 1400 2250 3900 8100
80 57 118 220 460 690 1300 2050 3700 7500

90 53 110 205 430 650 1220 1950 3450 7200
100 50 103 195 400 620 1150 1850 3250 6700
125 44 93 175 360 550 1020 1650 2950 6000
150 40 84 160 325 500 950 1500 2650 5500
175 37 77 145 300 460 850 1370 2450 5000
200 35 72 135 280 430 800 1280 2280 4600

IT IS IMPORTANT T O GUARD AGAINST GAS V AL VE FOULING
FROM CONTAMINANTS IN THE GAS W A YS. SUCH FOULING MA Y
CAUSE IMPROPER OPERA TION, FIRE OR EXPLOSION.

DISCONNECT THE HEATER AND ITS MANUAL GAS SHUTOFF
VAL VE FROM THE GAS SUPPL Y PIPING SYSTEM DURING ANY
SUPPLY PRESSURE TESTING EXCEEDING 1/2 PSIG. GAS
SUPPL Y LINE MUST BE CAPPED WHEN DISCONNECTED FROM
THE HEATER FOR TEST PRESSURES OF 1/2 PSIG OR LESS. THE
APPLIANCE NEED NOT BE DISCONNECTED, BUT MUST BE
ISOLATED FROM THE SUPPL Y PRESSURE TEST BY CLOSING
THE MANUAL GAS SHUTOFF V AL VE.

GAS PIPING AND DIRT LEG INST ALLATION

FIGURE 9

PURGING

Gas line purging is required with new piping or systems in which
air has entered.

CAUTION

PURGING SHOULD BE PERFORMED BY PERSONS EXPERIENCED
IN THIS TYPE GAS SERVICE. TO AVOID RISK OF FIRE OR
EXPLOSION, PURGE DISCHARGE MUST NOT ENTER CONFINED
AREAS OR SPACES WHERE IGNITION CAN OCCUR. THE AREA
MUST BE WELL VENTILA TED AND ALL SOURCES OF IGNITION
MUST BE INACTIVA TED OR REMOVED.

IF COPPER SUPPLY LINES ARE USED THEY MUST BE
INTERNALL Y TINNED AND CERTIFIED FOR GAS SERVICE. BEFORE
A TTACHING THE GAS LINE, BE SURE THA T ALL GAS PIPE IS
CLEAN ON THE INSIDE.

TO TRAP ANY DIRT OR FOREIGN MA TERIAL IN THE GAS SUPPL Y
LINE, A DIRT LEG (SOMETIMES CALLED SEDIMENT TRAP OR
DRIP LEG) MUST BE INCORPORA TED IN THE PIPING (SEE FIG .

9). THE DIRT LEG MUST BE READIL Y ACCESSIBLE AND NOT
SUBJECT TO FREEZING CONDITIONS. INSTALL IN
ACCORDANCE WITH RECOMMENDA TIONS OF SERVING GAS
SUPPLIERS. REFER TO THE LA TEST VERSION OF THE

NATIONAL

FUEL GAS CODE.

GAS METER SIZE — NATURAL GASES ONLY

Be sure the gas meter has sufficient capacity to supply the full
rated gas input of the water heater as well as the requirements
of all other gas fired equipment supplied by the meter. If gas
meter is too small, ask the gas company to install a larger meter
having adequate capacity.

GAS PRESSURE REGULATOR

The gas pressure regulator is built into the gas valve and is
equipped to operate on the gas specified on model and rating

9